User Manual

Page 5-56
200 BENCH PROCEDURES
Inspection
Refer back to Figure 5-67.
1. Visually inspect housing (24) for cracks
which may cause a leak. Replace housing if
damaged.
2. Check oil cooler bundle (22) for leaks by
pressurizing with air to 80 psi (552 kPa) and
submerging it in water. If a leak is detected,
replace with new bundle.
Assembly
Refer back to Figure 5-67.
Lubricate and install O-ring (3) in groove at
coolant outlet end of oil cooler housing (24).
1. Apply Permatex gasket sealer on coolant
inlet flange before installing gasket (23).
2. Install gasket (23) on coolant inlet end of
housing (24).
3. Apply Permatex gasket sealer on top of
gasket.
4. Install bundle (22). If necessary, tap bundle
with soft-faced hammer to seat bundle past
O-ring (3).
The alignment notch in the bundle end flange
must be positioned at the top for proper
installation.
5. Apply Permatex gasket sealer on bundle
end.
6. Place gasket on bundle end.
7. Apply Permatex gasket sealer on top of
gasket (21) before installing inlet cap (20).
8. Install coolant inlet end cap and secure with
six capscrews (19).
9. Torque coolant inlet end-cap capscrews to
20 lb-ft (27 N•m) using torque wrench
J 24405 or equivalent.
10. Apply Permatex sealant to both sides of
gasket (25) and install on mounting flange
(4) of housing.
11. Install coolant outlet end cap (2) with six
capscrews (26).
12. Torque coolant outlet end-cap capscrews to
20 lb-ft (27 N•m) using torque wrench
J 24406 or equivalent.
Refer to Figure 5-68.
13. Pressure-check oil cooler for leaks by
installing a test plate (4) with air fitting (3)
as follows:
a. Position a rubber gasket (5) and test
plate (4) on mounting flange (1) and
secure with mounting capscrews (2).
Figure 5-68 — Installing Test Plate
Refer to Figure 5-69.
b. Install a steel plate (2) with a rubber
gasket on oil outlet opening. Secure to
housing (1) with two capscrews (3).
c. Connect air line and pressurize to
80 psi (552 kPa). Submerge in water to
check for leaks.
1. Mounting flange
2. Capscrews
3. Air fitting
4. Test plate
5. Rubber gasket
200275a
1
3
2
4
5
2
5-101.bk Page 56 Friday, March 17, 2006 11:05 AM